Subaru Legacy (2005 year). Service manual — part 255

FU(H4DOTC)-45

FUEL INJECTION (FUEL SYSTEMS)

Fuel Tank

20) Connect the connector to fuel pump.

21) Install the service hole cover of fuel pump.

22) Install the rear seat.
23) Install the fuse of fuel pump to main fuse box.

C: INSPECTION

1) Check that the fuel tank is not holed, cracked or
otherwise damaged.
2) Make sure that the fuel pipe and fuel hose are
not cracked and those connections are tight.

(A) Bolt

(B) Grommet

FU-01125

FU-01124

(A)

(B)

(A)

FU(H4DOTC)-46

FUEL INJECTION (FUEL SYSTEMS)

Fuel Filler Pipe

23.Fuel Filler Pipe

A: REMOVAL

WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.
1) Disconnect the ground cable from battery.

2) Open the fuel filler flap lid, and remove the filler
cap.
3) Remove the screws which secure packing.

4) Lift-up the vehicle.
5) Remove the rear wheel RH.

6) Set a container under the vehicle and remove
the drain plug from fuel tank to drain fuel from fuel
tank.

7) Tighten the fuel drain plug.

NOTE:
Use a new gasket.

Tightening torque:

26 N

⋅

m (2.65 kgf-m, 19.2 ft-lb)

8) Remove the mud guard. <Ref. to EI-29, RE-
MOVAL, Mud Guard.>
9) Remove the rear sub frame. <Ref. to RS-23, RE-
MOVAL, Rear Sub Frame.>
10) Remove the bolts which hold fuel filler pipe
bracket on the body.

11) Loosen the clamp and disconnect the fuel filler
hose (A) and vent hose (B) from fuel filler pipe.

12) Remove the fuel filler pipe to under side of the
vehicle.

IN-00203

FU-00095

FU-00096

FU-01123

FU-01139

FU-01136

(A)

(B)

FU(H4DOTC)-47

FUEL INJECTION (FUEL SYSTEMS)

Fuel Filler Pipe

B: INSTALLATION

1) Open the fuel filler flap lid.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.

NOTE:
If the edges of rubber packing are folded toward in-
side, straighten it with a flat tip screwdriver.

4) Correctly insert the fuel filler hose (A) and vent
pipe (B) to the specified position, and then tighten
the clamp.

5) Tighten the bolts which hold fuel filler pipe brack-
et on the body.

Tightening torque:

7.5 N

⋅

m (0.76 kgf-m, 5.5 ft-lb)

6) Install the rear sub frame. <Ref. to RS-23, IN-
STALLATION, Rear Sub Frame.>
7) Install the mud guard. <Ref. to EI-29, INSTAL-
LATION, Mud Guard.>
8) Install the rear wheel RH.

9) Lower the vehicle.
10) Connect the ground cable to battery.

(1) Hose

(2) Clip or clamp

(3) Pipe

FU-00103

(A)

(C)

(B)

FU-01136

(A)

(B)

( 1 )

( 2 )

( 3 )

FU-00104

L

L/2

FU-01139

FU-00096

IN-00203

FU(H4DOTC)-48

FUEL INJECTION (FUEL SYSTEMS)

Fuel Pump

24.Fuel Pump

A: REMOVAL

WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.
• Reduce the fuel in the fuel tank to less than 3/
4 beforehand. Be careful that fuel may spill
when the fuel is more than 3/4.

NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure.
<Ref. to FU(H4DOTC)-39, RELEASING OF FUEL
PRESSURE, PROCEDURE, Fuel.>
2) Open the fuel filler flap lid, and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.

4) Lift-up the vehicle.
5) Remove the fuel tank protector.
6) Set a container under the vehicle and remove
drain plug from fuel tank to drain fuel from fuel tank.

7) Tighten the fuel drain plug.

NOTE:
Use a new gasket.

Tightening torque:

26 N

⋅

m (2.65 kgf-m, 19.2 ft-lb)

8) Remove the rear seat.

9) Remove the service hole cover.

(1) Remove the bolts (A).
(2) Push the grommet (B) down and remove
service hole cover.

10) Disconnect the connector from fuel pump.

11) Disconnect the quick connector and then dis-
connect the fuel delivery hose, return hose and jet
pump hose. <Ref. to FU(H4DOTC)-55, REMOVAL,
Fuel Delivery, Return and Evaporation Lines.>
12) Remove the nuts which install fuel pump as-
sembly onto fuel tank.

13) Remove the fuel pump assembly from fuel
tank.

IN-00203

FU-01123

(A) Delivery hose

(B) Return hose

(C) Jet pump hose

FU-01124

(A)

(B)

(A)

FU-01125

FU-01140

(A)

(B)

(C)